The key to reduction of errors in distribution is limiting the number of times every case is touched. Labatt’s solution was the just-in-time letdowns, which reduces the number of touches and therefore the number of errors. When the quantity in the pick slot goes to zero, the computer sends an automatic notice “just-in-time” to a forklift driver to retrieve the next oldest pallet from reserve inventory and put it in the pick slot. With the system, we’ve been able to optimize downstream productivity of our selectors, and eliminate the need to ever do another manual inventory count.
Labatt’s errors in the warehouse are less than 5 for every 10,000 cases shipped.